U.S. patent application number 12/092639 was filed with the patent office on 2009-05-28 for member for push button switch and method of manufacturing the same.
Invention is credited to Katsuhiko Kato, Hitoshi Uchiyama.
Application Number | 20090133997 12/092639 |
Document ID | / |
Family ID | 38023056 |
Filed Date | 2009-05-28 |
United States Patent
Application |
20090133997 |
Kind Code |
A1 |
Kato; Katsuhiko ; et
al. |
May 28, 2009 |
MEMBER FOR PUSH BUTTON SWITCH AND METHOD OF MANUFACTURING THE
SAME
Abstract
To obtain a member for a push button switch having a natural
metallic impression and an upscale impression; enabling a precise
arrangement of the push buttons; being capable of being made
thinner; and being difficult to get stained, there is provided a
member for a push button switch having a configuration in which a
gap between adjacent metal push buttons is filled with a
transparent organic polymer material, the transparent organic
polymer material including a transparent resin sheet extending from
an interior surface of the gap to a ceiling surface side of the
push button, and a transparent rubber-like elastic material
disposed inside the transparent resin sheet.
Inventors: |
Kato; Katsuhiko; (Gumma,
JP) ; Uchiyama; Hitoshi; (Saitama, JP) |
Correspondence
Address: |
PATENT DOCKET CLERK;COWAN, LIEBOWITZ & LATMAN, P.C.
1133 AVENUE OF THE AMERICAS
NEW YORK
NY
10036
US
|
Family ID: |
38023056 |
Appl. No.: |
12/092639 |
Filed: |
June 27, 2006 |
PCT Filed: |
June 27, 2006 |
PCT NO: |
PCT/JP2006/312822 |
371 Date: |
July 25, 2008 |
Current U.S.
Class: |
200/293 ;
156/243 |
Current CPC
Class: |
Y10T 29/49105 20150115;
H01H 2209/0021 20130101; H01H 13/88 20130101; H01H 2209/07
20130101; H01H 2209/002 20130101; H01H 13/704 20130101; H01H
2229/044 20130101 |
Class at
Publication: |
200/293 ;
156/243 |
International
Class: |
H01H 21/04 20060101
H01H021/04; B29C 47/02 20060101 B29C047/02 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 8, 2005 |
JP |
2005-323562 |
Mar 2, 2006 |
JP |
2006-055956 |
Claims
1. A member for a push button switch having a configuration in
which a gap between adjacent metal push buttons is filled with a
transparent organic polymer material, wherein the organic polymer
material comprises: a transparent resin sheet extending from an
interior surface of the gap to a ceiling surface side of the push
button; and a transparent rubber-like elastic material disposed
inside the transparent resin sheet.
2. A member for a push button switch according to claim 1, further
comprising a printing layer or a coloring layer at least in a
portion extending toward the ceiling surface side of the metal push
button in the transparent resin sheet.
3. A member for a push button switch according to claim 2, wherein
a surface of the metal push button has irregularities or a hole so
that a number, a symbol, a pattern, or a graphic is formed.
4. A member for a push button switch according to claim 2, wherein
a light emitting member is disposed between a surface opposite to
the metal push button in the transparent rubber-like elastic
material and a circuit board disposed therebelow.
5. A member for a push button switch according to claim 2, further
comprising a configuration in which a hole penetrating the metal
push button in a direction into and out of the metal push button is
formed so that the transparent organic polymer material is made to
extend from the hole toward the ceiling surface side of the metal
push button.
6. A member for a push button switch according to claim 2, further
comprising a sheet provided with a presser for pushing a switch
below the transparent rubber-like elastic material.
7. A member for a push button switch according to claim 1, wherein
the transparent organic polymer material projects from the surface
of the metal push button.
8. A method of manufacturing a member for a push button switch
having a configuration in which a gap between adjacent metal push
buttons is filled with a transparent organic polymer material, the
method comprising the steps of: attaching a transparent resin sheet
to one surface of a metal plate; forming a hole by performing
etching from a surface opposite to the surface having the
transparent resin sheet attached thereto in the metal plate to the
transparent resin sheet; and filling the hole with a transparent
rubber-like elastic material coated with the transparent resin
sheet by injecting the transparent rubber-like elastic material
from an outer of the transparent resin sheet toward the hole.
9. A method of manufacturing a member for a push button switch
having a configuration in which a gap between adjacent metal push
buttons is filled with a transparent organic polymer material, the
method comprising the steps of: forming a concave portion by
performing etching from one side of a metal plate to a halfway
position of a thickness of the metal plate; attaching a transparent
resin sheet to the metal plate so as to close the concave portion
of the one side; forming a hole connected to the concave portion
formed in advance by performing etching from a surface opposite to
the surface where the transparent resin sheet is attached in the
metal plate; and filling the hole with a transparent rubber-like
elastic material coated with the transparent resin sheet by
injecting the transparent rubber-like elastic material from an
outer of the transparent resin sheet toward the hole.
10. A method of manufacturing a member for a push button switch
according to claim 8, further comprising the step of forming a
printing layer or a coloring layer at least in a portion extending
toward a ceiling surface side of the metal push button in the
transparent resin sheet.
11. A method of manufacturing a member for a push button switch
according to claim 8, further comprising the step of making
irregularities or a hole in the surface of the metal push button to
form a number, a symbol, a pattern, or a graphic.
12. A method of manufacturing a member for a push button switch
according to claim 8, further comprising the step of disposing a
light emitting member between the surface opposite to the metal
push button in the transparent rubber-like elastic material and a
circuit board disposed therebelow.
13. A method of manufacturing a member for a push button switch
according to claim 8, further comprising the step of forming a hole
penetrating the metal push button in a direction into and out of
the metal push button, wherein in the step of filling the hole with
the transparent rubber-like elastic material, the transparent
organic polymer material is made to extend from the hole to the
ceiling surface side of the metal push button.
14. A method of manufacturing a member for a push button switch
according to claim 8, further comprising the step of providing a
sheet including a presser for pressing a switch below the
transparent rubber-like elastic material.
15. A method of manufacturing a member for a push button switch
according to claim 8, wherein in the step of filling the hole with
the transparent rubber-like elastic material, the transparent
organic polymer material is made to project from the surface of the
metal push button.
16. A method of manufacturing a member for a push button switch
according to claim 9, further comprising the step of forming a
printing layer or a coloring layer at least in a portion extending
toward a ceiling surface side of the metal push button in the
transparent resin sheet.
17. A method of manufacturing a member for a push button switch
according to claim 9, further comprising the step of making
irregularities or a hole in the surface of the metal push button to
form a number, a symbol, a pattern, or a graphic.
18. A method of manufacturing a member for a push button switch
according to claim 9, further comprising the step of disposing a
light emitting member between the surface opposite to the metal
push button in the transparent rubber-like elastic material and a
circuit board disposed therebelow.
19. A method of manufacturing a member for a push button switch
according to claim 9, further comprising the step of forming a hole
penetrating the metal push button in a direction into and out of
the metal push button, wherein in the step of filling the hole with
the transparent rubber-like elastic material, the transparent
organic polymer material is made to extend from the hole to the
ceiling surface side of the metal push button.
20. A method of manufacturing a member for a push button switch
according to claim 9, further comprising the step of providing a
sheet including a presser for pressing a switch below the
transparent rubber-like elastic material.
21. A method of manufacturing a member for a push button switch
according to claim 9, wherein in the step of filling the hole with
the transparent rubber-like elastic material, the transparent
organic polymer material is made to project from the surface of the
metal push button.
Description
TECHNICAL FIELD
[0001] The present invention relates to a member for a push button
switch used in a control panel of an electronic device and a method
of manufacturing the same.
BACKGROUND ART
[0002] In the industry of members for push button switches used in
control panels of electronic devices, particularly those of
cellular phones, the diversifications for the design and function
has further increased. In recent years, as a member for a push
button switch used in the electronic device such as a cellular
phone, a member having a metallic appearance is used as a high-end
design. The member for a push button switch having a metallic
appearance has the structure in which a plated layer, a resin
molded portion, and a base rubber are layered in the stated order
from the push button surface side. The plated layer is, for
example, nickel-plated, copper-plated, or chrome-plated (for
example, see Patent Document 1). Further, in order to protect the
plated layer, a technology of forming a transparent resin coated
layer on a surface of the plated layer is known. Also, there is
known a member for a push button switch, in which a resin film
subjected to metal evaporation is processed by drawing, and the
interior thereof is filled with a core material formed of a resin
or a rubber with the resin film being used as a outer layer to be
integrated.
[0003] In order to further increase an upscale impression of
electronic devices such as cellular phones, there is also known a
member for a push button switch having a structure where a metal
push button is attached to a surface of a flexible sheet such as a
silicone rubber (for example, see Patent Document 2). Besides,
considering the use in a dark place or designability, in this
member for a push button switch, a hole having a shape such as a
number is made in the push button itself and a transparent resin is
fit into the hole. As a result, the number or the like is easily
visible when exposed to light from a rear side of the push
button.
[0004] In addition, the demands for making electronic devices such
as cellular phones thinner are strong. Therefore, a member for a
push button switch mounted onto an electronic device such as a
cellular phone is required to become thinner as well.
[0005] Patent Document 1: JP 2003-129248 A (for example, Scope of
Claims)
[0006] Patent Document 2: KR 100454203 B (for example, Scope of
Claims)
[0007] However, the aforementioned member for a push button switch
has the following problems. In the case where a member for a push
button switch having metallic appearance is manufactured by forming
a plated layer on a surface of a resin molded portion, the plated
layer is liable to be peeled off, which makes it difficult to be
used for a long period of time. Further, providing a metallic
appearance through plating process results in poor productivity,
which has a bad influence on the environment. In addition, though
taking on a metallic-like texture to a certain extent, the member
for a push button switch subjected to the plating process can
hardly be provided with a natural metallic appearance. Also in the
case of a resin push button having a metallic appearance, because
the resin is used as a material, some extent of thickness is
required for ensuring intensity. The aforementioned matter is an
obstacle to the attempt to make a member for a push button switch
thinner.
[0008] On the other hand, in the case where a metal push button is
attached to a surface of a flexible sheet such as a silicone
rubber, because the metal push button is used, the problems
described above hardly occur. However, the step of accurately
positioning each metal push button on a keypad to be bonded thereto
is extremely complicated. Further, the flexible sheet such as a
silicone rubber exists in a gap between the metal push buttons, and
thus there arises a problem in that a friction coefficient becomes
relatively large in the gap portion, and the gap is easy to get
dirty or stained.
[0009] The present invention has been made in view of the above
problems, and an object thereof is to provide a member for a push
button switch which has a natural metallic impression and upscale
impression, enables a precise arrangement of the push buttons, can
be made thinner, and is difficult to get stained.
OBJECTS AND SUMMARY OF THE INVENTION
[0010] In order to achieve the aforementioned object, the present
invention provides a member for a push button switch having a
configuration where a gap between adjacent metal push buttons is
filled with a transparent organic polymer material, in which the
organic polymer material includes a transparent resin sheet
extending from an interior surface of the gap to a ceiling surface
side of the push button and a transparent rubber-like elastic
material disposed inside the transparent resin sheet.
[0011] As described above, the push button is a member made of
metal, there arises no problem such as a reduction in adhesion
between a plated layer and a resin molded portion. Accordingly, a
natural metallic impression can be attained. Further, use of the
metal push button makes it possible to make the metal push button
thinner with ease. Further, because the member for a push button
switch according to the present invention has a structure where a
gap between the adjacent metal push buttons is filled with the
transparent rubber-like elastic material covered with the
transparent resin sheet, the transparent resin sheet having a
relatively small friction coefficient is provided on the gap which
is placed between the adjacent metal push buttons. As a result, the
gap is difficult to get stained or dusty. Further, the metal push
buttons are not individually attached to an organic polymer
material, and thus accurate arrangement of the push buttons is
accomplished.
[0012] Further, another present invention provides, in the
preceding invention, a member for a push button switch including a
printing layer or a coloring layer at least in a portion extending
toward the ceiling surface side of the metal push button in the
transparent resin sheet. As a result, the function for the button
can be indicated on the each metal push button. In particular, when
light is irradiated from a rear side of the transparent rubber-like
elastic material, the portion of the printing layer or the coloring
layer can be identified even in a dark place, which facilitates the
use in the dark place. In the case of the structure where a hole is
provided in the metal push button and the transparent resin sheet
can be seen, the printing layer or the coloring layer may be
provided also on the rear side of the metal push button.
[0013] Further, still another present invention provides, in each
of the preceding inventions, a member for a push button switch in
which a surface of the metal push button is provided with
irregularities or a hole to form a number, a symbol, a pattern, or
a graphic. Since the irregularities or the hole is thus formed in
the surface of the metal push button, there is an extremely low
possibility that the number or the like made by the irregularities
or the hole may be erased through an operation of the push button.
The pattern formed by the irregularities or the hole can be formed
by processing such as laser processing, press processing, etching,
mat finish, and hairline finish. Also in the case where a hole is
provided in the metal push button, when light is irradiated from
the rear side of the push button, the portion of the pattern is
easily visible. For this reason, in particular, the another
invention is useful when an electronic device using the member for
a push button switch is used in a dark place.
[0014] Further, yet another present invention provides, in each of
the preceding inventions, a member for a push button switch having
a light emitting member disposed between a surface opposite to the
metal push button in the transparent rubber-like elastic material
and a circuit board disposed therebelow. Thus, a gap between the
adjacent push buttons can emit light. As a result, a position of
each push button is easily visible, and the another present
invention is easily used when an electronic device using the member
for a push button switch is used also in a dark place. As the light
emitting member, for example, an LED or EL sheet is preferably
used.
[0015] Further, still another present invention provides, in each
of the preceding inventions, a member for a push button switch
having a configuration where a hole penetrating the metal push
button in a direction into and out of the metal push button is
formed to make the transparent organic polymer material extend from
the hole to the top surface of the metal push button. For this
reason, when light is irradiated from the rear side of the push
button, it is getting easier to distinct the push button.
Accordingly, in particular, the another invention is useful when an
electronic device using the member for a push button switch is used
in a dark place. In addition, because the hole is filled with the
transparent organic polymer material, penetration of grit and dust
from the outside can be prevented.
[0016] Further, still another present invention provides, in each
of the preceding inventions, a member for a push button switch
having a sheet provided with a presser for pressing a switch below
the transparent rubber-like elastic material. The sheet provided
with the presser is attached from the beginning in this way, and
thus an electronic device such as a cellular phone is easily
assembled.
[0017] Further, still another present invention provides, in each
of the preceding inventions, a member for a push button switch in
which the transparent organic polymer material is made to project
from the surface of the metal push button. For this reason,
compared with the case where the transparent organic polymer
material is dented from the surface of the metal push button,
accumulation of grit and dirt in the gap between the adjacent metal
push buttons can be effectively prevented. Also in the case where
the hole penetrating the metal push button itself is filled with
the transparent organic polymer material, distinguishing the push
button itself becomes easier. In addition, compared with the case
where the transparent organic polymer material is dented from the
surface of the metal push button, accumulation of grit and dirt in
the portion of the transparent organic polymer material filled in
the penetrating hole can be effectively prevented. Here, in the
case where the surface of the push button is not a planar shape,
the description "project from the surface of the metal push button"
means that the transparent organic polymer material projects from
the surface portion of the metal push button located on an outer
edge of the transparent organic polymer material. Accordingly, even
in the case where a transparent organic polymer material located in
the gap between the adjacent metal push buttons is lower than a top
portion of a metal push button which has a convex-shaped center,
the height of the transparent organic polymer material projects
from the surface of the metal push button if being higher than a
periphery of the push button.
[0018] Further, still another present invention provides a method
of manufacturing a member for a push button switch having a
configuration in which a gap between adjacent metal push buttons is
filled with a transparent organic polymer material, the method
including the steps of: attaching a transparent resin sheet to one
surface of a metal plate; forming a hole by performing etching from
a surface opposite to the one surface having the transparent resin
sheet attached thereto in the metal plate to the transparent resin
sheet; and filling the hole with a transparent rubber-like elastic
material coated with the transparent resin sheet by injecting the
transparent rubber-like elastic material from an outer of the
transparent resin sheet toward the hole.
[0019] In this manner, because the hole is made also from one
surface of the metal plate to the resin sheet attached to the
surface opposite thereto, even in the case of a member for a push
button switch having a configuration where each push button is
separated, the member for a push button switch can be manufactured
without separating the metal plate for each push button.
Accordingly, a position of the push button exclusively depends on
accuracy in the step of drawing a region which is to be etched.
Thus, compared with the step of attaching each push button, a push
button can be arranged more easily as well as accurately. Further,
with the use of a injection pressure of the transparent rubber-like
elastic material, the transparent resin sheet is pushed into the
hole, and thus the transparent resin sheet and the transparent
rubber-like elastic material do not need to be filled separately.
Consequently, the manufacturing step can be simplified.
[0020] Further, still another present invention provides a method
of manufacturing a member for a push button switch having a
configuration in which a gap between adjacent metal push buttons is
filled with a transparent organic polymer material, the method
including the steps of: forming a concave portion by performing
etching from one side of a metal plate to a halfway position of a
thickness of the metal plate; attaching a transparent resin sheet
to the metal plate so as to close the concave portion of the one
side; forming a hole connected to the concave portion formed in
advance by performing etching from a surface opposite to the
surface where the transparent resin sheet is attached; and filling
the hole with a transparent rubber-like elastic material coated
with the transparent resin sheet by injecting the transparent
rubber-like elastic material from an outer of the transparent resin
sheet toward the hole.
[0021] In this manner, the metal plate is etched from both sides
thereof and the hole connected to the concave portion in a
predetermined position having the thickness of the metal plate,
whereby an edge portion of the hole provided on the both sides of
the metal plate is easy to be formed clearly. Accordingly, the push
button can be processed into an accurate shape. Further, as in the
case of the manufacturing method described above, even in the case
of a member for a push button switch having a configuration where
each push button is separated, the member for a push button switch
can be manufactured without separating the metal plate for each
push button. Accordingly, a position of the push button exclusively
depends on accuracy in the step of drawing a region which is to be
etched. Thus, compared with the step of attaching each push button,
the push button can be arranged easily as well as accurately.
[0022] Further, with the use of a injection pressure of the
transparent rubber-like elastic material, the transparent resin
sheet is pushed into a hole, and thus the transparent resin sheet
and the transparent rubber-like elastic material do not need to be
filled separately. As a result, the manufacturing step can be
simplified.
[0023] Further, still another present invention provides, in each
of the preceding inventions, a method of manufacturing a member for
a push button switch further including the step of forming a
printing layer or a coloring layer at least in a portion extending
toward a ceiling surface side of the metal push button in the
transparent resin sheet. Adopting of such a manufacturing method
enables to indicate a function of each metal push button. In
particular, when light is irradiated from a rear side of the
transparent rubber-like elastic material, a portion of the printing
layer or the coloring layer can be identified even in a dark place,
whereby a member for a push button switch of an electronic device,
which is easily used in the dark place, can be manufactured.
Further, in the case where a hole is provided in the metal push
button such that the transparent resin sheet is seen, the printing
layer or the coloring layer may be provided also in a rear side of
the metal push button.
[0024] Further, still another present invention provides, in each
of the preceding inventions, a method of manufacturing a member for
a push button switch further including the step of forming a
number, a symbol, a pattern, or a graphic by providing
irregularities or a hole on a surface of the metal push button. In
this manner, the step of forming irregularities or a hole on the
surface of the metal push button is used, so there can be
manufactured a member for a push button switch with an extremely
low possibility that the number or the like made by the
irregularities or the hole disappears through an operation of the
push button. The pattern formed by the irregularities or the hole
can be formed by process such as laser processing, press
processing, etching, mat finish, and hairline finish. Further, in
the case where a hole is made in the metal push button, when light
is irradiated from the rear side of the push button, the portion of
the pattern is easily visible. As a result, in particular, a member
for a push button switch of an electronic device, which is easily
used in a dark place, can be manufactured.
[0025] Further, still another present invention provides, in each
of the preceding inventions, a method of manufacturing a member for
a push button switch further including the step of disposing a
light emitting member between a surface opposite to the metal push
button in the transparent rubber-like elastic material and a
circuit board disposed therebelow. Adopting of such a manufacturing
method makes the gap between the push buttons emit light. As a
result, a position of each push button is easily visible, and a
member for a push button switch of an electronic device, which is
easily used in a dark place, can be manufactured. As the light
emitting member, for example, an LED or EL sheet can be preferably
used.
[0026] Further, still another present invention provides, in each
of the preceding inventions, a method of manufacturing a member for
a push button switch further including the step of forming a hole
penetrating the metal push button in a direction into and out of
the metal push button, in which, in the step of filling with the
transparent rubber-like elastic material, the transparent organic
polymer material is made to extend from the hole to a ceiling
surface side of the metal push button. When such a manufacturing
method is adopted, irradiation of light from the rear side of the
push button makes it possible to easily distinguish push buttons.
For this reason, in particular, the another present invention is
useful when an electronic device using the member for a push button
switch is used in a dark place. In addition, because the hole is
filled with the transparent organic polymer material, penetration
of grit and dirt can be prevented.
[0027] Further, still another present invention provides, in each
of the preceding inventions, a method of manufacturing a member for
a push button switch further including the step of providing a
sheet provided with a presser for pressing a switch below the
transparent rubber-like elastic material. Accordingly, an
electronic device such as a cellular phone can be assembled with
more ease using the member for a push button switch obtained
through this manufacturing method.
[0028] Further, still another present invention provides, in each
of the preceding inventions, a method of manufacturing a member for
a push button switch, in which, in the step of filling with the
transparent rubber-like elastic material, the transparent organic
polymer material is made to project from a surface of the metal
push button. Adopting of such a manufacturing method makes it
possible to effectively prevent accumulation of grit and dirt in
the gap between the metal push buttons, compared with the case
where the transparent organic polymer material is dented from the
surface of the metal push button. Also in the case where the hole
penetrating the metal push button itself is filled with the
transparent organic polymer material, the push button itself is
easily distinguished. Moreover, compared with the case where the
transparent organic polymer material is dented from the surface of
the metal push button, a portion of the transparent organic polymer
material filled into the penetrating hole can be effectively
prevented from being filled with grit and dirt.
[0029] As a member of the metal push button forming the member for
a push button switch according to the present invention, in
addition to stainless steel, aluminum, magnesium, copper, zinc,
titanium, or their alloy is preferably used, and in particular,
stainless steel member is more preferably used. However, the
aforementioned metals are cited as an example, and other metal
material may be used.
[0030] Further, the material of the transparent organic polymer
material forming the member for a push button switch according to
the present invention includes the transparent resin sheet and the
transparent rubber-like elastic material. As a material of the
transparent resin sheet, in addition to PET, a transparent resin
abundant in extendibility, such as urethane, polycarbonate,
polystyrene, or polyester resin, may be used. Further, a silicone
rubber is particularly preferable as the material of the
transparent rubber-like elastic material. However, the transparent
rubber-like elastic material is not limited to the silicone rubber,
and for example, a urethane rubber may be used as other transparent
rubber-like elastic material. It is assumed that the term
"transparent" referred to in the present invention broadly includes
"transparent and colorless", "transparent and colored", and
"semitransparent".
[0031] The metal push buttons may be in a sate of being separated
each other or a state where a plurality thereof are gathered.
Moreover, the push buttons may be not in a state of being
completely separated, but in a state where a part of a
circumference of each of the push buttons may be notched to connect
to another push button.
[0032] According to the present invention, there can be provided
the member for a push button switch, which has a natural metallic
impression and an upscale impression; enables a precise arrangement
of the push buttons; can be made thinner; and is difficult to get
stained.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] FIGS. 1(a) and 1(b) are views in which FIG. 1(a) is a plan
view of a member for a push button switch according to a first
embodiment of the present invention, and FIG. 1(b) is a
cross-sectional view taken along the line A-A of the plane view of
FIG. 1(a).
[0034] FIG. 2 is a partially enlarged view of FIG. 1(b) which is
the cross-sectional view taken along the line A-A of FIG. 1(a).
[0035] FIG. 3 is a flowchart showing an example of a method of
manufacturing the member for a push button switch according to the
first embodiment of the present invention.
[0036] FIGS. 4(a) through 4(f) are views showing a state in each
step of manufacturing the member for a push button switch according
to the first embodiment of the present invention.
[0037] FIG. 5 is a flowchart showing an example of a method of
manufacturing a member for a push button switch according to a
second embodiment of the present invention.
[0038] FIGS. 6(a) through 6(f) are views showing a state in each
step of manufacturing the member for a push button switch according
to the second embodiment of the present invention.
[0039] FIGS. 7(a) and 7(b) are partially enlarged views of a
cross-sectional view when a member for a push button switch
according to a third embodiment of the present invention is cut by
the same line as the line A-A of FIG. 1(a), in which FIG. 7(a)
shows an example where a transparent resin coated layer formed on a
surface of a metal push button is flush with a transparent organic
polymer material, and FIG. 7(b) shows an example where the
transparent organic polymer material projects from the transparent
resin coated layer toward a surface side.
[0040] FIGS. 8(a) and 8(b) are views in which FIG. 8(a) is a plan
view of a member for a push button switch according to a fourth
embodiment of the present invention, and FIG. 8(b) is a
cross-sectional view taken along the line B-B of the plan view of
FIG. 8(a).
[0041] FIGS. 9(a) and 9(b) are views in which FIG. 9(a) is a plan
view of a member for a push button switch according to a fifth
embodiment of the present invention, and FIG. 9(b) is a
cross-sectional view taken along the line C-C of the plan view of
FIG. 9(a).
[0042] FIG. 10 includes a view showing a member for a push button
switch according to a sixth embodiment of the present invention and
an enlarged view showing one of a plurality of metal push buttons
forming the member for a push button switch.
[0043] FIG. 11 includes a cross-sectional view of the one of the
plurality of metal push buttons, which is taken along the line D-D
of FIG. 10 and a view showing a substrate disposed below the metal
push button.
[0044] FIG. 12 is a flowchart showing an example of a method of
manufacturing the member for a push button switch according to the
sixth embodiment of the present invention.
[0045] FIGS. 13(a) through 13(e) are views showing a state in each
step of manufacturing the member for a push button switch according
to the sixth embodiment of the present invention.
[0046] FIG. 14 includes a cross-sectional view of one of metal push
buttons forming a member for a push button switch according to a
seventh embodiment of the present invention, which is taken along
the line D-D of FIG. 10, and a view showing a substrate disposed
below the metal push button.
[0047] FIG. 15 is a flowchart showing an example of a method of
manufacturing the member for a push button switch according to the
seventh embodiment of the present invention.
[0048] FIGS. 16(a) through 16(g) are views showing a state in each
step of manufacturing the member for a push button switch according
to the seventh embodiment of the present invention.
[0049] FIG. 17 is a plan view of a member for a push button switch
according to an eighth embodiment of the present invention.
[0050] FIG. 18 is a cross-sectional view taken along the line E-E
of FIG. 17.
[0051] FIG. 19 is a flowchart showing an example of a method of
manufacturing the member for a push button switch according to the
eighth embodiment of the present invention.
[0052] FIGS. 20(a) through 20(f) are views showing a state in each
step of manufacturing the member for a push button switch according
to the eighth embodiment of the present invention.
[0053] FIG. 21 is a cross-sectional view of a member for a push
button switch according to a ninth embodiment of the present
invention, which is taken along the line E-E of FIG. 17.
DESCRIPTION OF SYMBOLS
[0054] 1 member for push button switch [0055] 10 metal push button
[0056] 10a metal plate [0057] 11 transparent resin sheet [0058] 12
transparent rubber-like elastic material [0059] 12a presser [0060]
13 transparent resin coated layer [0061] 14 light emitting member
[0062] 15 transparent organic polymer material [0063] 16 pusher
sheet (sheet) [0064] 16a presser [0065] 20 hole [0066] 21 concave
portion [0067] 25 printing layer, coloring layer [0068] 30 member
for push button switch [0069] 40 member for push button switch
[0070] 50 member for push button switch [0071] 60 member for push
button switch [0072] 61 substrate [0073] 62 fixed contact (switch)
[0074] 63 fixed contact (switch) [0075] 64 metal disc spring [0076]
70 member for push button switch [0077] 80 member for push button
switch [0078] 90 member for push button switch
DETAILED DESCRIPTION OF THE INVENTION
[0079] Hereinafter, each preferable embodiment of a member for a
push button switch according to the present invention and a method
of manufacturing the same is described in detail with reference to
the drawings. In each embodiment, a description is made on an
example where the member for a push button switch is used as an
operating unit of a cellular phone by way of example. However, the
present invention is not limited to each embodiment described
below, and is applicable to an operating unit of an electronic
device other than the cellular phone, such as a laptop computer and
an electronic notebook.
First Embodiment
[0080] FIGS. 1(a) and 1(b) include a plan view (a) of a member for
a push button switch according to a first embodiment of the present
invention, and a cross-sectional view (b) taken along the line A-A
of FIG. 1(a). FIG. 2 is a partially enlarged view of the
cross-sectional view (b) taken along the line A-A.
[0081] A member for a push button switch 1 mainly includes a
plurality of metal push buttons 10, a transparent organic polymer
material 15 (including a transparent resin sheet 11 and a
transparent rubber-like elastic material 12) disposed to fill a gap
between the adjacent metal push buttons 10, a transparent resin
coated layer 13 applied on a surface of each metal push button 10,
and a light emitting member 14 disposed on a rear side (side
opposite to the metal push button 10) of the transparent organic
polymer material 15.
[0082] The metal push button 10 is an operating part in the member
for a push button switch 1, which can be pushed. On an operating
surface of the metal push button 10, patterns of both a number and
an alphabet are formed in a concave shape by pressing. Note that
the pattern formed on the operating surface may be a pattern other
than the number and the alphabet (for example, symbol or graphic),
and may be formed through a processing method such as laser
processing, etching, mat finish, and hairline finish. Also, as a
material of the metal push button 10, stainless steel is used.
However, aluminum, magnesium, copper, zinc, titanium, or a various
alloy can also be used. Note that a thickness of a metal plate 10a
for forming the metal push button 10 is preferably within a range
of equal to or more than 0.1 mm to equal to or less than 0.5 mm,
and more preferably within a range of equal to or more than 0.15 mm
to equal to or less than 0.25 mm. In case the thickness is in such
a range, deformation due to operation is difficult to appear, and
also the demands of decreasing the thickness are met. However, the
thickness of the metal plate 10a is not limited to the
above-mentioned range, and may be set to less than 0.1 mm or more
than 0.5 mm.
[0083] For the transparent resin coated layer 13 formed on the
operating surface of the metal push button 10, in addition to a
transparent synthetic resin such as an acrylic, polycarbonate,
epoxy, oxetane synthetic resin having a high hardness, a
transparent synthetic resin such as urethane or fluorinated
synthetic resin having a lower hardness than the transparent
synthetic resin having high hardness may be used. In the case where
there is aimed a prevention of injuries caused by a touch during
the operation and a contact with a metal burr or the like while
maintaining a metallic appearance of the metal push button 10, as
the transparent resin coated layer 13, in particular, using a resin
paint is more preferable. However, the aforementioned resin paint
is just an example, and other resin paint having high hardness may
be used. Note that the transparent resin coated layer 13 is not an
essential layer. Through selection of a metal type, a processing
which does not cause a burr or the like, if a touch during the
operation is good and there is a low possibility of the danger of
injuries, the transparent resin coated layer 13 may not be
formed.
[0084] The transparent resin sheet 11 forming the transparent
organic polymer material 15 is a transparent sheet-like resin
having extendibility, and, for example, is an organic polymer
chemical compound such as polyethylene terephthalate (PET),
polybutylene terephthalate (PBT), polycarbonate (PC), and urethane,
or their compound. For example, because being excellent in drawing
characteristics, an alloy of PC and PBT can be preferably used.
Further, the transparent rubber-like elastic material 12 forming
the transparent organic polymer material 15 is, for example, a
silicone rubber or a urethane rubber. However, as the transparent
rubber-like elastic material 12, other material (for example,
thermoplastic elastomer) may be used. A thickness of the
transparent resin sheet 11 is preferably within a range of equal to
or more than 0.03 mm to equal to or less than 0.2 mm, and more
preferably within a range of equal to or more than 0.05 mm to equal
to or less than 0.1 mm. As described later, this is because the
transparent resin sheet 11 smoothly extends to the gap between the
adjacent metal push buttons 10 without making a hole by filling
with the transparent rubber-like elastic material 12. However, the
thickness of the transparent resin sheet 11 may be set to less than
0.03 mm or more than 0.2 mm.
[0085] As shown in FIG. 1(b), the transparent resin sheet 11 is
arranged to cover a periphery of the transparent rubber-like
elastic material 12 in the gap between the metal push buttons 10,
so the transparent rubber-like elastic material 12 is not exposed
to the operating surface side of the metal push button 10.
Accordingly, it is difficult to get stained or dusty on the gap
between the metal push buttons 10. Moreover, the member for a push
button switch 1 is structured so that the metal push button 10 is
substantially flush with the transparent resin sheet 11 disposed in
the gap between the adjacent push buttons 10. As a result, further,
grit and dirt hardly adhere to the gap between the adjacent metal
push buttons 10.
[0086] Further, the light emitting member 14 is disposed between
the transparent rubber-like elastic material 12 and a circuit board
(not shown) arranged therebelow. As the light emitting member 14,
an EL sheet can be preferably used. However, the light emitting
member 14 (for example, LED) other than the EL sheet may be used.
In this manner, when the light emitting member 14 is arranged below
the transparent rubber-like elastic material 12, the transparent
resin sheet 11 can emit light through light emission of the light
emitting member 14. Therefore, even in a dark place, the member for
a push button switch 1 can be easily operated.
[0087] Further, when a hole is made in the operating surface of the
metal push button 10 to indicate a function (for example, number
and alphabet) of each metal push button 10, in the case of making
the light emitting member 14 emit light, light in a shape
corresponding to a shape of the hole is visible on the operating
surface side through the transparent rubber-like elastic material
12, the transparent resin sheet 11, and the hole. For this reason,
each metal push button 10 can be used more easily in a dark place.
Note that, without making a hole, the concave portion is formed
with the almost full depth from the operating surface of the metal
push button 10 to the surface opposed thereto and a bottom of the
concave portion is made thinner than other regions, whereby light
can be made to pass corresponding to the shape of the concave
portion. In the case where the concave portion is formed, there can
be obtained an effect that each metal push button 10 can be used
much more easily in a dark place.
[0088] Next, a description is made on an example of a method of
manufacturing the member for a push button switch 1 according to
the first embodiment of the present invention.
[0089] FIG. 3 is a flowchart showing an example of the method of
manufacturing the member for a push button switch 1 according to
the first embodiment of the present invention. FIGS. 4(a) through
4(f) are views showing a state in each step of manufacturing the
member for a push button switch 1 according to the first
embodiment.
[0090] First, the transparent resin sheet 11 is attached to one
surface side of the metal plate 10a in a state before processing
the metal push button 10 (Step S101). In this attachment, although
a thermosetting adhesive which demonstrates an adhesive function by
heat is preferably used, a double-sided tape and an adhesive
capable of becoming cured at room temperature may be used. Through
this Step S101, the member for a push button switch 1 becomes the
state shown in FIG. 4(b) from the state shown in FIG. 4(a). Next,
on a surface which becomes a push button on the opposite side of
the surface to which the transparent resin sheet 11 in the metal
plate 10a is attached, a pattern is formed by press (Step
S102).
[0091] Next, until reaching the transparent resin sheet 11, the
metal plate 10a is etched (Step S103). As a result, a hole 20 is
formed. Through this Step S103, the member for a push button switch
1 becomes the state shown in FIG. 4(c) from the state shown in FIG.
4(b). In this embodiment, a photo-etching is used as an etching
method having merits such as design freedom, excellent processing
accuracy, and low initial cost. Note that, as a method of forming
the hole 20 other than the photo-etching, for example, a machining
process using a tool for high-precision processing may be used.
[0092] Next, the transparent resin coated layer 13 is formed on the
surface of the metal push button 10 (Step S104). This step is
conducted, for example, by a method such as spray, coat, and paint.
This step is conducted to bring the transparent resin coated layer
13 into contact with the metal push button 10, to prevent hand
injuries caused by a contact with a burr or the like generated in
the metal push button 10, and to prevent a touch feeling from being
deteriorated. Also, this step is conducted to prevent the pattern
formed on the operating surface of the metal push button 10 from
getting stained. Through this Step S104, the member for a push
button switch 1 becomes the state shown in FIG. 4(d) from the state
shown in FIG. 4(c).
[0093] Next, the transparent rubber-like elastic material 12 is
filled at high pressure from the side where the transparent resin
sheet 11 is attached toward the hole 20 (Step S105). As a result,
the transparent rubber-like elastic material 12 is filled in the
hole 20 while pushing the transparent resin sheet 11 to the hole
20. It is preferable that a pressure during filling the transparent
rubber-like elastic material 12 be made equal to or less than 200
kgf/cm.sup.2, and a temperature during the filling be within a
range of 100 to 180.degree. C. However, the pressure and the
temperature are both not limited to the aforementioned range, and
can be arbitrarily changed according to the various conditions such
as a material of the transparent resin sheet 11 and the transparent
rubber-like elastic material 12. Through this Step S105, the member
for a push button switch 1 becomes the state shown in FIG. 4(e)
from the state shown in FIG. 4(d). In other words, the transparent
resin sheet 11 is extended from a rear surface of the metal push
button 10 along an inner surface of the gap so as to form a top
surface of the gap. Further, the transparent rubber-like elastic
material 12 exists from the rear side of the transparent resin
sheet 11 to the rear side of the metal push button 10.
[0094] Next, the light emitting member 14 is attached from a rear
side of the transparent rubber-like elastic material 12 (Step
S106). As an attaching method, an adhesive, a double-sided tape, or
the like is preferably used. Through this Step S106, the member for
a push button switch 1 becomes the state shown in FIG. 4(f) from
the state shown in FIG. 4(e).
Second Embodiment
[0095] Next, a description is made on the member for a push button
switch according to the present invention and a method of
manufacturing the same according to the second embodiment.
[0096] The member for a push button switch according to the second
embodiment has the same structure as that of the member for a push
button switch 1 according to the first embodiment described above.
Thus, also in the member for a push button switch according to the
second embodiment, the same symbols as those in the member for a
push button switch 1 according to the first embodiment are used.
Also, because component parts composing the member for a push
button switch 1 according to the second embodiment is the same as
component parts composing the member for a push button switch 1
according to the first embodiment, the same symbols are used and
the description overlapping the first embodiment is omitted.
[0097] FIG. 5 is a flowchart showing an example of the method of
manufacturing the member for a push button switch 1 according to
the second embodiment. FIGS. 6(a) through 6(f) are views showing a
state in each step of manufacturing the member for a push button
switch 1 according to the second embodiment.
[0098] First, from one surface side of the metal plate 10a, etching
is performed to the middle of a thickness of the metal plate 10a to
form a concave portion 21 (Step S201). In the etching, as in the
case of the first embodiment, a photo-etching is preferably used.
Through Step S201, the member for a push button switch 1 becomes
the state shown in FIG. 6(a).
[0099] Next, the transparent resin sheet 11 is attached to a
surface of an opening side of the concave portion 21 in the metal
plate 10a (Step S202). In this attachment, although a thermosetting
adhesive which demonstrates an adhesive function by heat is
preferably used, a double-sided tape or an adhesive capable of
becoming cured at room temperature may be used. Through this Step
S202, the member for a push button switch 1 becomes the state shown
in FIG. 6(b) from the state shown in FIG. 6(a). Next, on a surface
which becomes a push button on the opposite side of the surface to
which the transparent resin sheet 11 in the metal plate 10a is
attached, a pattern is formed by press (Step S203).
[0100] Next, etching is performed from a side opposite to the
opening side of the concave portion 21 to form the hole 20
connecting with the concave portion 21 (Step S204). Through this
Step S204, the member for a push button switch 1 becomes the state
shown in FIG. 6(c) from the state shown in FIG. 6(b).
[0101] Next, the transparent resin coated layer 13 is formed on the
side opposite to the surface having the transparent resin sheet 11
attached in the metal push button 10 (Step S205). Through this Step
S205, the member for a push button switch 1 becomes the state shown
in FIG. 6(d) from the state shown in FIG. 6(c).
[0102] Next, the transparent rubber-like elastic material 12 is
filled from a side where the transparent resin sheet 11 is attached
toward the hole 20 at high pressure (Step S206). As a result, the
transparent rubber-like elastic material 12 is filled in the hole
20 while pushing the transparent resin sheet 11 to the hole 20.
Through this Step S206, the member for a push button switch 1
becomes the state shown in FIG. 6(e) from the state shown in FIG.
6(d). In other words, the transparent resin sheet 11 is extended
from a rear surface of the metal push button 10 along an inner
surface of the gap so as to form a top surface of the gap. Further,
the transparent rubber-like elastic material 12 exists from a rear
side of the transparent resin sheet 11 to the rear side of the
metal push button 10.
[0103] Next, the light emitting member 14 is attached from the rear
side of the transparent rubber-like elastic material 12 (Step
S207). Through this Step S207, the member for a push button switch
1 becomes the state shown in FIG. 6(f) from the state shown in FIG.
6(e).
[0104] When the manufacturing steps shown in FIGS. 6(a) through
6(f) and FIGS. 7(a) and 7(b) are used, the transparent resin sheet
11 is hardly to be damaged during etching. In other words, after
the formation of the concave portion 21, etching can be performed
from the side opposite to the opening surface of the concave
portion 21 and can be stopped at a time when connecting with the
concave portion 21, whereby the transparent resin sheet 11 is
hardly to be damaged by etching. Further, etching is performed from
the both sides of the metal plate 10a to form the hole 20.
Accordingly, an edge is easily formed on the both opening portions
of the hole 20, and an edge of the metal push button 10 is easily
made. Thus, when the transparent organic polymer material 15 is
filled, an interface between the metal push button 10 and the
transparent organic polymer material 15 becomes clear.
Third Embodiment
[0105] Next, a description is made on the member for a push button
switch according to the present invention and a method of
manufacturing the same according to the third embodiment.
[0106] A member for a push button switch 30 according to the third
embodiment has component parts common to the member for a push
button switch 1 according to the first embodiment described above.
Thus, the same symbols are used in the component parts which are
common to the member for a push button switch 30 according to the
third embodiment and the member for a push button switch 1
according to the first embodiment, and an overlapping description
is omitted.
[0107] FIGS. 7(a) and 7(b) are partially enlarged views of a
cross-sectional view when the member for a push button switch 30
according to the third embodiment is taken along the line similar
to the line A-A of FIG. 1(a). FIG. 7(a) shows an example in a state
where the transparent resin coated layer 13 formed on the surface
of the metal push button 10 is flush with the transparent organic
polymer material 15, and FIG. 7(b) shows an example in a state
where the transparent organic polymer material 15 projects from the
transparent resin coated layer 13 toward a surface side.
[0108] As apparent from the comparison of FIGS. 7(a) and 7(b) and
FIG. 2, the member for a push button switch 30 according to the
third embodiment is different from the member for a push button
switch 1 according to the first embodiment in that a printing layer
25 or a coloring layer 25 (hereinafter, referred to as "printing
layer or the like" 25) exists between the transparent resin sheet
11 and the transparent rubber-like elastic material 12. In FIGS.
7(a) and 7(b), the printing layer or the like 25 is represented by
a black heavy line. Further, the member for a push button switch 30
according to the third embodiment is different from the member for
a push button switch 1 according to the first embodiment in that a
urethane resin is used as the transparent resin sheet 11.
[0109] The printing layer or the like 25 may be formed in advance
in the transparent resin sheet 11 or the transparent rubber-like
elastic material 12, and may be formed separately before or after
attaching the transparent resin sheet 11 to the metal plate 10a. In
the latter case, the formation step of the printing layer or the
like 25 is preferably performed before Step S202 or between Step
S202 and Step S206 of FIG. 5. The printing layer or the like 25 is
formed so that printing or coloring is visible from a surface side
of the member for a push button switch 30 through irradiation of
light from the rear side of the transparent rubber-like elastic
material 12. As a specific formation method of the printing layer
or the like 25, for example, there can be included a method of
converting a desired design to data by a CAD system to make a
drawing on the transparent resin sheet 11 or the transparent
rubber-like elastic material 12 based on the created data. As a
formation method of the printing layer or the like 25, for example,
a method such as a screen printing or a curved surface printing can
be adopted. Note that the printing layer or the like 25 may be
formed between the surface of the metal push button 10 and the
transparent resin sheet 11.
[0110] When a urethane resin is used as the transparent resin sheet
11, higher extendibility can be expected compared with PET.
Accordingly, even in the case where a pressure at a time of filling
the transparent rubber-like elastic material 12 is relatively
small, or even in the case where a thickness of the metal push
button 10 is large, the transparent resin sheet 11 and the
transparent rubber-like elastic material 12 can be easily filled in
the gap between the adjacent metal push buttons 10.
[0111] Further, the member for a push button switch 30 shown in
FIG. 7(b) is different from the member for a push button switch 30
shown in FIG. 7(a) in having a structure in which the transparent
organic polymer material 15 projects from the transparent resin
coated layer 13 formed on the surface of the metal push button 10
toward the surface side. When the gap between the metal push
buttons 10 is made to have a convex shape in this manner, a
position of each metal push button 10 can be easily grasped by
touch. In particular, if a part or all of the periphery of a push
button having a number "5" is made to have a convex shape, there
can be provided a role similar to a role of a projection of the
surface of the push button having the number "5" in an existing
cellular phone. In addition, it is more advantageous when the
transparent organic polymer material 15 is made to project than
when a part of the surface of the metal push button 10 is made to
project, in view of protection of user's fingers. The structure
shown in FIG. 7(b) can be easily formed, for example, by providing
a concave portion on the concave interior surface of a molding die.
Further, it is possible that, among the metal push buttons 10, a
hole having the shape of the number "5" is provided in the push
button having the number "5" so that the transparent organic
polymer material 15 is projected from the rear side to the hole,
whereby there can be provided the role similar to the role of the
projection of the surface of the push button having the number "5"
in the existing cellular phone. Further, the transparent organic
polymer material 15 may be projected not only to the surface of the
push button having the number "5" but also to a surface of a push
button having other number such that each push button is recognized
by touch.
Fourth Embodiment
[0112] Next, a description is made on the member for a push button
switch according to the present invention and a method of
manufacturing the same according to the fourth embodiment.
[0113] A member for a push button switch 40 according to the fourth
embodiment has component parts common to the member for a push
button switch 1 according to the first embodiment described above.
For this reason, the same symbols are used in the component parts
common to the member for a push button switch 40 according to the
fourth embodiment and the member for a push button switch 1
according to the first embodiment, and an overlapping description
is omitted. Further, in the manufacturing method according to the
fourth embodiment, any of each manufacturing method according to
the first embodiment and the second embodiment, which is described
above, may be adopted.
[0114] FIGS. 8(a) and 8(b) include a plan view FIG. 8(a) of the
member for a push button switch 40 according to the fourth
embodiment of the present invention, and a cross-sectional view
FIG. 8(b) taken along the line B-B of the plan view of FIG.
8(a).
[0115] Each metal push buttons 10 and an external frame 41 are
integrated in the member for a push button switch 40. The member
for a push button switch 40 has a structure in which the
transparent organic polymer material 15 (including the transparent
resin sheet 11 and the transparent rubber-like elastic material 12)
is filled from a rear side thereof in the gaps between the adjacent
metal push buttons 10 floating like islands, and in a gap between
the metal push buttons 10 and the external frame 41. The member for
a push button switch 40 has the structure similar to that of the
member for a push button switch 1 according to the first
embodiment. With such a structure, unity between the metal push
buttons 10 and the external frame 41 can be obtained with more
ease.
Fifth Embodiment
[0116] Next, a description is made on the member for a push button
switch according to the present invention and a method of
manufacturing the same according to the fifth embodiment.
[0117] A member for a push button switch 50 according to the fifth
embodiment has component parts common to the member for a push
button switch 1 according to the first embodiment described above.
For this reason, the same symbols are used in the component parts
common to the member for a push button switch 50 according to the
fifth embodiment and the member for a push button switch 1
according to the first embodiment, and an overlapping description
is omitted. Further, in the manufacturing method according to the
fifth embodiment, any of each manufacturing method according to the
first embodiment and the second embodiment, which is described
above, may be adopted.
[0118] FIGS. 9(a) and 9(b) include a plan view FIG. 9(a) of the
member for a push button switch 50 according to the fifth
embodiment of the present invention, and a cross-sectional view
FIG. 9(b) taken along the line C-C of the plan view of FIG.
9(a).
[0119] In the member for a push button switch 50, a part of each
metal push button 10 is not separated but co-joined with each other
through a part of a cut. From a rear side of the cut, the
transparent organic polymer material 15 is filled. In this manner,
in the case of forming a region where each metal push button 10 is
not completely separated, the transparent organic polymer material
15 is filled in a cut dividing the adjacent metal push buttons 10,
whereby the same operational advantages as those of the member for
a push button switch 1, 30, and 40 according to each embodiment
described above can be obtained.
Sixth Embodiment
[0120] Next, a description is made on the member for a push button
switch according to the present invention and a method of
manufacturing the same according to the sixth embodiment.
[0121] A member for a push button switch 60 according to the sixth
embodiment has component parts common to the member for a push
button switch 1 according to the first embodiment described above.
For this reason, the same symbols are used in the component parts
common to the member for a push button switch 60 according to the
sixth embodiment and the member for a push button switch 1
according to the first embodiment, and an overlapping description
is omitted.
[0122] FIG. 10 includes a view showing the member for a push button
switch 60 according to the sixth embodiment and an enlarged view
showing one of a plurality of metal push buttons 10 forming the
member for a push button switch 60. In FIG. 10, the surface of the
metal push button 10 is coated with the transparent resin coated
layer 13, so a reference numeral denoting the metal push button 10
is presented by "10(13)". FIG. 11 includes a cross-sectional view
of one of the metal push buttons 10, which is taken along the line
D-D of FIG. 10, and a view showing a substrate 61 disposed below
the metal push button 10.
[0123] As shown in FIG. 11, the transparent organic polymer
material 15 is in a state of projecting from the transparent resin
coated layer 13 toward the surface side. A hole having a shape of a
number, a character, or a symbol which is to be indicated thereon
is made in the metal push button 10, and the transparent organic
polymer 15 is made to project from the rear side to the hole,
whereby each metal push button 10 can be easily recognized by
touch. Moreover, the designability as a three-dimensional character
can be improved.
[0124] The transparent rubber-like elastic material 12 has a
presser 12a for pushing a fixed contact (switch). Switches 62, 62,
and 63 are arranged in the substrate 61. A metal disc spring 64
fixes its opening edges to the switches 62, 62. In space inside the
metal disc spring 64, the switch 63 electrically connected to the
substrate 61 is disposed so as not to be contact with the metal
disc spring 64. On a surface of the metal disc spring 64 and a
surface of the substrate 61, the light emitting member 14 such as
an EL sheet is disposed.
[0125] When the metal push button 10 is pushed, the presser 12a
formed below the transparent rubber-like elastic material 12 pushes
the metal disc spring 64 from above the light emitting member 14.
As a result, the metal disc spring 64 is elastically dented and
pushes the switch 63. When the pushing of the metal push button 10
is released, the presser 12a is released from the metal disc spring
64, and the metal disc spring 64 also returns to the original
hemispherical shape. Accordingly, the pushing of the switch 63 is
also released.
[0126] Next, an example of the method of manufacturing the member
for a push button switch 60 according to the sixth embodiment is
described.
[0127] FIG. 12 is a flowchart showing an example of the method of
manufacturing the member for a push button switch 60 according to
the sixth embodiment. FIGS. 13(a) through 13(e) are views showing a
state in each step of manufacturing the member for a push button
switch 60 according to the sixth embodiment.
[0128] Step S301 to Step S304 of the flowchart shown in FIG. 12 are
the same steps as Step S101 to Step S104 of the flowchart shown in
FIG. 3, respectively. Similarly, a state shown in each of FIGS.
13(a) to 13(d) is the same state of each of FIGS. 4(a) to 4(d)
shown in FIG. 4. However, in the case of the member for a push
button switch 60 according to the sixth embodiment, the hole 20 is
formed in the metal push button 10 itself, and the transparent
organic polymer material 15 is filled also in the hole 20.
Accordingly, in Step S303 shown in FIG. 12, etching is performed
such that the hole 20 is formed not only in the gap between the
adjacent metal push buttons 10, but also in the metal push button
10 itself. Further, FIG. 13 show a state where a cross-sectional
part of the metal push button 10 shown in FIG. 11 changes as the
manufacturing process advances. As for the manufacturing process,
many parts thereof overlap the manufacturing process described in
the first embodiment, so a description thereof is omitted. In the
sixth embodiment, parts significantly different from the first
embodiment are that the transparent rubber-like elastic material 12
has the shape having the presser 12a, and that the step (Step S106)
of attaching the light emitting member 14 to a bottom surface of
the transparent rubber-like elastic material 12 does not exist.
This is because the light emitting member 14 may be disposed on the
substrate 61 side.
[0129] Note that, as in the case of the embodiment described above,
the printing layer or the like 25 may be formed in the transparent
resin sheet 11 in advance. The timing of the formation may be
before or after attaching the transparent resin sheet 11 to the
metal plate 10a.
Seventh Embodiment
[0130] Next, a description is made on the member for a push button
switch according to the present invention and a method of
manufacturing the same according to the seventh embodiment.
[0131] A member for a push button switch 70 according to the
seventh embodiment has component parts common to the member for a
push button switch 1 according to the first embodiment described
above. For this reason, the same symbols are used in the component
parts common to the member for a push button switch 70 according to
the seventh embodiment and the member for a push button switch 1
according to the first embodiment, and an overlapping description
is omitted.
[0132] FIG. 14 includes a cross-sectional view of one of the metal
push buttons 10 forming the member for a push button switch 70
according to the seventh embodiment, which is taken along the same
line as the line D-D of FIG. 10, and a view showing the substrate
61 disposed below the metal push button 10.
[0133] As shown in FIG. 14, the transparent organic polymer
material 15 is in a state of projecting from the transparent resin
coated layer 13 toward the surface side. A hole having a shape of a
number, a character, or a symbol which is to be indicated thereon
is made in the metal push button 10, and the transparent organic
polymer 15 is made to project to the hole from the rear side,
whereby each metal push button 10 can be easily recognized by
touch. Moreover, the designability as a three-dimensional character
can be improved.
[0134] The light emitting member 14 such as an EL sheet is disposed
below the transparent rubber-like elastic material 12 of the member
for a push button switch 70, and a pusher sheet (sheet) 16 having a
presser 16a is disposed therebelow. The pusher sheet 16 may be
transparent or opaque. In this manner, the light emitting member 14
may be disposed on the member for a push button switch 70 side, not
on the substrate 61 side. The fixed contacts (switches) 62, 62, and
63 are arranged in the substrate 61. The metal disc spring 64 fixes
its opening edges to the switches 62, 62. In space inside the metal
disc spring 64, the switch 63 electrically connected to the
substrate 61 is disposed so as not to be contact with the metal
disc spring 64.
[0135] When the metal push button 10 is pushed, the presser 16a of
the pusher sheet 16 pushes the metal disc spring 64. As a result,
the metal disc spring 64 is elastically dented and pushes the
switch 63. When the pushing of the metal push button 10 is
released, the presser 16a is released from the metal disc spring
64, and the metal disc spring 64 also returns to the original
hemispherical shape. Accordingly, the pushing of the switch 63 is
also released.
[0136] Next, an example of the method of manufacturing the member
for a push button switch 70 according to the seventh embodiment is
described.
[0137] FIG. 15 is a flowchart showing an example of the method of
manufacturing the member for a push button switch 70 according to
the seventh embodiment. FIGS. 16(a) through 16(g) are views showing
a state in each step of manufacturing the member for a push button
switch 70 according to the seventh embodiment.
[0138] Step S401 to Step S406 of the flowchart shown in FIG. 15 are
the same steps of Step S101 to Step S106 of the flowchart shown in
FIG. 3, respectively. Similarly, the state shown in each of FIGS.
16(a) to 16(f) is the same state of each of FIGS. 4(a) to 4(f).
However, in the case of the member for a push button switch 70
according to the seventh embodiment, the hole 20 is formed in the
metal push button 10 itself, and the transparent organic polymer
material 15 is filled also in the hole 20. Accordingly, in Step
S403 shown in FIG. 15, etching is performed such that the hole 20
is formed not only in the gap between the adjacent metal push
buttons 10 but also in the metal push button 10 itself. Further,
FIG. 16 show a state where a cross-sectional part of the metal push
button 10 shown in FIG. 14 changes as the manufacturing process
advances. The manufacturing process overlaps the manufacturing
process described in the first embodiment, so a description thereof
is omitted. In the seventh embodiment, a part different from the
first embodiment is that the step (Step S407) of attaching the
pusher sheet 16 having the presser 16a to below the light emitting
member 14 exists. The pusher sheet 16 is a necessary member because
of the structure of an electronic device such as a cellular phone.
However, it is assumed that the member for a push button switch
according to the present invention is broadly interpreted to
include both of the state where the pusher sheet is attached and
the state where the pusher sheet is not attached. Note that, after
Step S405, the step of attaching the light emitting member 14 to
the pusher sheet 16 may be performed, and after that, the step of
attaching the light emitting member 14 side of the member obtained
in the attaching step to the transparent rubber-like elastic
material 12 may be performed. Further, after Step S405, there may
be performed the step of integrally forming the light emitting
member 14 and the rubber-like elastic material having the presser
16a, and the step of attaching the light emitting member 14 side
obtained in the integrally forming step to the transparent
rubber-like elastic material 12.
[0139] Note that, as in the case of the embodiment described above,
the printing layer or the like 25 may be formed in the transparent
resin sheet 11 in advance. The timing of the formation may be
before or after attaching the transparent resin sheet 11 to the
metal plate 10a.
Eighth Embodiment
[0140] Next, a description is made on the member for a push button
switch according to the present invention and a method of
manufacturing the same according to the eighth embodiment.
[0141] A member for a push button switch 80 according to the eighth
embodiment has component parts common to the member for a push
button switch 1 according to the first embodiment described above.
For this reason, the same symbols are used in the component parts
common to the member for a push button switch 80 according to the
eighth embodiment and the member for a push button switch 1
according to the first embodiment, and an overlapping description
is omitted.
[0142] FIG. 17 is a plain view of the member for a push button
switch 80 according to the eighth embodiment. FIG. 18 is a
cross-sectional view taken along the line E-E of FIG. 17. In FIG.
18, X is a metal push button 10 having "1" indicated thereon, which
is shown in FIG. 17, Y is a metal push button 10 having "2"
indicated thereon, which is shown in FIG. 17, and Z is a metal push
button 10 having "3" indicated thereon, which is shown in FIG.
17.
[0143] As shown in FIG. 18, the transparent resin sheet 11 is
disposed on the rear side of the metal push button 10. Another
transparent resin sheet (In FIG. 18, represented by a black heavy
line) 11 is disposed over a rear side of the transparent resin
sheet 11, an interior surface of the hole inside the metal push
button 10, and the top surface of the hole. The transparent
rubber-like elastic material 12 is disposed on the rear side of the
another transparent resin sheet 11. A transparent organic polymer
material 15 composed of the another transparent resin sheet 11 and
the transparent rubber-like elastic material 12 is attached so as
to fill the gap between the adjacent metal push buttons 10 and the
hole inside the metal push button 10 from the rear surface of the
metal push button 10. At a position below the metal push button 10
in the transparent rubber-like elastic material 12, the presser 12a
is formed. Note that a light emitting member (not shown) is
disposed on the substrate side which is disposed below the member
for a push button switch 80, not on the member for a push button
switch 80 side.
[0144] Next, an example of the method of manufacturing the member
for a push button switch 80 according to the eighth embodiment is
described.
[0145] FIG. 19 is a flowchart showing an example of the method of
manufacturing the member for a push button switch 80 according to
the eighth embodiment. FIGS. 20(a) through 20(f) are views showing
a state in each step of manufacturing the member for a push button
switch 80 according to the eighth embodiment.
[0146] First, the transparent resin sheet 11 is attached to one
surface side of the metal plate 10a which is in a state before
processing the metal push button 10 (Step S501). Although a
thermosetting adhesive which demonstrates an adhesive function by
heat is preferably used in this attachment, a double-sided tape or
an adhesive capable of becoming cured at room temperature may also
be used. Through this Step S501, the member for a push button
switch 80 becomes the state shown in FIG. 20(b) from the state
shown in FIG. 20(a). Next, a through hole 81 is formed on a part of
the transparent resin sheet 11 (Step S502). This through hole 81 is
formed according to a shape of a character or the like which is
indicated on the metal push button 10 and each of its surface. When
the through hole 81 is provided on the entire periphery of the
metal push button 10, the metal push button 10 drops. Thus, the
through hole 81 is provided so as to leave a part of the periphery.
Through Step S502, the member for a push button switch 80 becomes
the state shown in FIG. 20(c) from the state shown in FIG.
20(b).
[0147] Next, the metal plate 10a is etched from the side opposite
to the transparent resin sheet 11 to the transparent resin sheet 11
(Step S503). As a result, the hole 20 is formed. Note that the
transparent resin sheet 11 does not exist in the part of the
through hole 81. Through Step S503, the member for a push button
switch 80 becomes the state shown in FIG. 20(d) from the state
shown in FIG. 20(c).
[0148] Next, another transparent resin sheet 11 is made to overlap
the transparent rubber-like elastic material 12, whereby a molding
having a convex portion for filling the hole 20 and the presser 12a
below each metal push button 10 is manufactured (Step S504).
Although the preferable molding method is an injection molding, a
molding method other than this may be adopted. Through Step S504,
the transparent organic polymer material 15 as shown in FIG. 20(e)
is obtained.
[0149] Next, the component member including the metal push button
10 manufactured in Steps S501 to S503 and the transparent resin
sheet 11 is attached to the transparent organic polymer material 15
manufactured in Step S504 (Step S505). In this manner, the member
for a push button switch 80 shown in FIG. 20(f) is obtained.
[0150] Note that, in Step S504, only the transparent rubber-like
elastic material 12 can be attached to the component member
including the metal push button 10 and the transparent resin sheet
11 without using the another transparent resin sheet 11. Further, a
decorative printing layer can be formed in the transparent organic
polymer material 15 interposed inside the metal push button 10. In
this case, the decorative printing layer may be formed in at least
any of the transparent rubber-like elastic material 12 and the
another transparent resin sheet 11.
Ninth Embodiment
[0151] Next, a description is made on the member for a push button
switch according to the present invention and a method of
manufacturing the same according to the ninth embodiment.
[0152] A member for a push button switch 90 according to the ninth
embodiment has component parts common to the member for a push
button switch 1 according to the first embodiment described above.
For this reason, the same symbols are used in the component parts
common to the member for a push button switch 90 according to the
ninth embodiment and the member for a push button switch 1
according to the first embodiment, and an overlapping description
is omitted.
[0153] FIG. 21 is a cross-sectional view of the member for a push
button switch 90 according to the ninth embodiment, which is taken
along the same line as the line E-E shown in FIG. 17.
[0154] The member for a push button switch 90 according to the
ninth embodiment has the transparent resin sheet 11 on the surface
side of the metal push button 10. Also, from a surface side
opposite to the transparent resin sheet 11, the transparent organic
polymer material 15 composed of the another transparent resin sheet
11 and the transparent rubber-like elastic material 12 is disposed
so as to fill the gap between the adjacent metal push buttons 10
and a hole inside each metal push button 10. At a position below
the metal push button 10 in the transparent rubber-like elastic
material 12, the presser 12a is formed.
[0155] The member for a push button switch 90 of a structure shown
in FIG. 21 can be manufactured by, after the state shown in FIG.
20b, etching from the surface side opposite to the attached
transparent resin sheet 11 and attaching the transparent organic
polymer material 15 shown in FIG. 20e to the side of the hole 20
which is formed through the etching.
[0156] The member for a push button switch 90 shown in FIG. 21 can
be manufactured also by a manufacturing method different from the
aforementioned manufacturing method, which is described below.
First, the transparent resin sheet 11 is attached to one surface of
the metal plate 10a, and etching is performed from the side
opposite to the transparent resin sheet 11. After that, another
transparent resin sheet 11 is attached to an opening side of the
hole 20 formed through the etching. Next, from any of the
transparent resin sheets 11 on the both sides, the transparent
rubber-like elastic material 12 is press-fitted toward the hole
20.
[0157] Further, a printing layer can be formed on a part or entire
of the rear side of the transparent resin sheet 11 attached to the
outer surface of the metal push button 10.
[0158] Each preferable embodiment of the member for a push button
switch according to the present invention and the method of
manufacturing the same has been described above, but the present
invention is not limited thereto and can be performed through
various modifications.
[0159] For instance, attachment of the metal plate 10a to the
transparent resin sheet 11 may be performed by roughing a surface
of the metal plate 10a and depositing the transparent resin sheet
11 to the roughed surface, not performed through an adhesive
material such as an adhesive and a double-sided tape.
[0160] Also, in the case of filling the hole 20 with both the
transparent rubber-like elastic material 12 and the transparent
resin sheet 11, when the transparent resin sheet 11 is subjected to
a primer processing and the transparent rubber-like elastic
material 12 is supplied to the surface subjected to the primer
processing, adhesiveness between the transparent resin sheet 11 and
the transparent rubber-like elastic material 12 is improved, which
is preferable.
[0161] Also, in the method of manufacturing the member for a push
button switch according to the first embodiment of the present
invention, Step S101 and Step S102 of the flowchart shown in FIG. 3
may be performed in reverse. Also, Step S104 may be performed after
Step S105 or Step S106. Further, at least any one of Step S102,
Step S104, and Step S106 may not be performed.
[0162] Also, in the method of manufacturing the member for a push
button switch according to the second embodiment of the present
invention, Step S203 of the flowchart shown in FIG. 5 may be
performed before Step S201, Step S202, or Step S205. Also, Step
S205 may be performed after Step S206 or Step S207. Further, at
least any one of Step S203, Step 205, and Step 207 may not be
performed.
[0163] Also, in the method of manufacturing the member for a push
button switch according to the sixth embodiment of the present
invention, Step S301 and Step S302 of the flowchart shown in FIG.
12 may be performed in reverse. Also, Step S304 may be performed
after Step S305. Further, at least any one of Step S302 and Step
304 may not be performed.
[0164] Also, in the method of manufacturing the member for a push
button switch according to the seventh embodiment of the present
invention, Step S401 and Step S402 of the flowchart shown in FIG.
15 may be performed in reverse. Also, Step S404 may be performed
after Step S405, Step S406, or Step 407. Further, at least any one
of Step S402, Step S404, and Step 406 may not be performed.
[0165] Also, in the method of manufacturing the member for a push
button switch according to the eighth embodiment of the present
invention, Step S501 and Step S502 of the flowchart shown in FIG.
19 may be performed in reverse. Also, Step S504 may be performed
before any of Step S501 to Step S503.
INDUSTRIAL APPLICABILITY
[0166] The present invention can be used in the industry where a
member for a push button switch of an electronic device is
manufactured or used.
* * * * *